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Directed Energy Deposition (DED) is a metal additive manufacturing process capable of building and repairing large, complex metal parts from a wide range of alloys. Its flexibility makes it attractive for multiple industrial applications,…

In this study, we leverage the massive amount of multi-modal on-machine metrology data generated from Laser Powder Directed Energy Deposition (LP-DED) to construct a comprehensive surrogate model of the 3D printing process. By employing…

Systems and Control · Electrical Eng. & Systems 2025-04-04 Michael Juhasz , Eric Chin , Youngsoo Choi , Joseph T. McKeown , Saad Khairallah

In additive manufacturing (AM), particularly for laser-based metal AM, process optimization is crucial to the quality of products and the efficiency of production. The identification of optimal process parameters out of a vast parameter…

Materials Science · Physics 2024-07-25 Xiao Shang , Evelyn Li , Ajay Talbot , Haitao Wen , Tianyi Lyu , Jiahui Zhang , Yu Zou

Numerically solving partial differential equations (PDEs) can be challenging and computationally expensive. This has led to the development of reduced-order models (ROMs) that are accurate but faster than full order models (FOMs). Recently,…

Computational Engineering, Finance, and Science · Computer Science 2024-05-30 Christophe Bonneville , Youngsoo Choi , Debojyoti Ghosh , Jonathan L. Belof

In Laser Powder Bed Fusion (LPBF), the applied laser energy produces high thermal gradients that lead to unacceptable final part distortion. Accurate distortion prediction is essential for optimizing the 3D printing process and…

Machine Learning · Computer Science 2024-12-09 Indu Kant Deo , Youngsoo Choi , Saad A. Khairallah , Alexandre Reikher , Maria Strantza

Directed energy deposition (DED), a metal additive manufacturing process, is highly susceptible to process-induced defects such as geometric deviations, lack of fusion, and poor surface finish. This work presents a build-height-synchronized…

Optics · Physics 2026-01-14 Guanzhong Hu , Wenpan Li , Rujing Zha , Ping Guo

Directed energy deposition (DED) produces complex thermo-mechanical responses that can lead to distortion and reduced dimensional accuracy of a manufactured part. Thermo-mechanical finite element simulations are widely used to estimate…

The investigation of fluid-solid systems is very important in a lot of industrial processes. From a computational point of view, the simulation of such systems is very expensive, especially when a huge number of parametric configurations…

Hot-wire directed energy deposition using a laser beam (DED-LB/w) is a method of metal additive manufacturing (AM) that has benefits of high material utilization and deposition rate, but parts manufactured by DED-LB/w suffer from a…

Systems and Control · Electrical Eng. & Systems 2023-10-20 M. Rahmani Dehaghani , Atieh Sahraeidolatkhaneh , Morgan Nilsen , Fredrik Sikström , Pouyan Sajadi , Yifan Tang , G. Gary Wang

This contribution describes the implementation of a data--driven shape optimization pipeline in a naval architecture application. We adopt reduced order models (ROMs) in order to improve the efficiency of the overall optimization, keeping a…

Numerical Analysis · Mathematics 2024-01-22 Nicola Demo , Giulio Ortali , Gianluca Gustin , Gianluigi Rozza , Gianpiero Lavini

In course of this work, we examine the process of plastic profile extrusion, where a polymer melt is shaped inside the so-called extrusion die and fixed in its shape by solidification in the downstream calibration unit. More precise, we…

Numerical Analysis · Mathematics 2022-09-08 Daniel Hilger , Norbert Hosters

Spatial Atomic Layer Deposition (SALD) is a recent approach that is up to two orders of magnitude faster than conventional ALD, and that can be performed at atmospheric pressure and even in the open air. Previous works have exploited these…

Laser-directed-energy deposition (DED) offers advantages in additive manufacturing (AM) for creating intricate geometries and material grading. Yet, challenges like material inconsistency and part variability remain, mainly due to its…

Machine Learning · Computer Science 2024-02-28 Vispi Karkaria , Anthony Goeckner , Rujing Zha , Jie Chen , Jianjing Zhang , Qi Zhu , Jian Cao , Robert X. Gao , Wei Chen

An open source two-dimensional (2D) thermal finite element (FE) model of the Directed Energy Deposition (DED) process is developed using the Python-based FEniCS framework. The model incrementally deposits material ahead of the laser focus…

Directed Energy Deposition (DED) processes offer one of the most versatile current techniques to additively manufacture and repair metallic components that have generatively designed complex geometries, and with compositional control. When…

Applied Physics · Physics 2020-11-25 Michael Liu , Abhishek Kumar , Satish Bukkapatnam , Mathew Kuttolamadom

A parametric adaptive physics-informed greedy Latent Space Dynamics Identification (gLaSDI) method is proposed for accurate, efficient, and robust data-driven reduced-order modeling of high-dimensional nonlinear dynamical systems. In the…

Systems and Control · Electrical Eng. & Systems 2023-07-19 Xiaolong He , Youngsoo Choi , William D. Fries , Jon Belof , Jiun-Shyan Chen

Advanced Manufacturing (AM) has gained significant interest in the nuclear community for its potential application on nuclear materials. One challenge is to obtain desired material properties via controlling the manufacturing process during…

Machine Learning · Statistics 2023-08-21 Mahmoud Yaseen , Dewen Yushu , Peter German , Xu Wu

Numerical solvers of partial differential equations (PDEs) have been widely employed for simulating physical systems. However, the computational cost remains a major bottleneck in various scientific and engineering applications, which has…

Reduced order modeling (ROM) techniques are numerical methods that approximate the solution of parametric partial differential equation (PDE) by properly combining the high-fidelity solutions of the problem obtained for several…

Numerical Analysis · Mathematics 2023-08-08 M. Girfoglio , L. Scandurra , F. Ballarin , G. Infantino , F. Nicolò , A. Montalto , G. Rozza , R. Scrofani , M. Comisso , F. Musumeci

We investigate the use of reduced-order modelling to run discrete element simulations at higher speeds. Taking a data-driven approach, we run many offline simulations in advance and train a model to predict the velocity field from the mass…

Computational Physics · Physics 2021-03-02 Erik Wallin , Martin Servin
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